Stable shape-selective catalyst for aromatic alkylation and methods of using and preparing

Abstract

A catalyst and method of forming a catalyst for use in aromatic alkylation involves treating a zeolite, which may be a ZSM-5 zeolite, with a phosphorus-containing compound. The phosphorus-treated zeolite is combined with a binder material. The bound phosphorus-treated zeolite is treated with an aqueous solution of a hydrogenating metal compound by contacting the bound phosphorus-treated zeolite with the aqueous solution and separating the aqueous solution from the bound phosphorus-treated zeolite to form a hydrogenating-metal-containing zeolite catalyst. The catalyst may be used in preparing an alkyl aromatic product by contacting a hydrogenating-metal-containing zeolite catalyst with an aromatic alkylation feed of an aromatic compound and an alkylating agent under reaction conditions suitable for aromatic alkylation.

We claim: 
     
       1. A hydrogenating-metal-containing zeolite catalyst for use in aromatic alkylation, the catalyst formed by
 treating a ZSM-5 zeolite with a phosphorus-containing compound to form a phosphorus-treated zeolite; 
 combining the phosphorus-treated zeolite with a binder material to form a bound phosphorus-treated zeolite; 
 treating the bound phosphorus-treated zeolite with an aqueous solution of a hydrogenating metal compound by contacting the bound phosphorus-treated zeolite with the aqueous solution to form a hydrogenating-metal-containing zeolite in an aqueous medium, wherein the hydrogenating metal is Group VIII transition metal; 
 separating the aqueous medium from the bound phosphorus-treated zeolite using a non-evaporative separation technique; and 
 calcining to form a hydrogenating-metal-containing zeolite catalyst. 
 
     
     
       2. The catalyst of  claim 1 , wherein:
 the hydrogenating metal is selected from at least one of nickel, palladium and platinum. 
 
     
     
       3. The catalyst of  claim 1 , wherein:
 the calcining is at a temperature of about 400° C. or higher. 
 
     
     
       4. The catalyst of  claim 1 , wherein:
 the hydrogenating metal is present in the catalyst in an amount of about 0.03% to about 5% by total weight of catalyst. 
 
     
     
       5. The catalyst of  claim 1 , wherein:
 the catalyst contains about 0.01% to about 15% phosphorus by total weight of catalyst. 
 
     
     
       6. The catalyst of  claim 1 , wherein:
 the binder comprises an alumina binder. 
 
     
     
       7. The catalyst of  claim 1 , wherein:
 the binder is present in the catalyst in an amount of about 1% to about 99% by total weight of the catalyst. 
 
     
     
       8. The catalyst of  claim 2 , wherein the hydrogenating metal comprises nickel. 
     
     
       9. The catalyst of  claim 8 , wherein the nickel is present in the catalyst in an amount of about 0.01% to about 5% by total weight of the catalyst. 
     
     
       10. The catalyst of  claim 9 , wherein the nickel is present in the catalyst in an amount of about 0.03% to about 2.0% by total weight of the catalyst. 
     
     
       11. The catalyst of  claim 8 , wherein:
 the catalyst contains about 0.01% to about 15% phosphorus by total weight of catalyst; and 
 the binder comprises an alumina binder. 
 
     
     
       12. The catalyst of  claim 1 , wherein the temperature of the aqueous solution is maintained at a temperature below the boiling point of the aqueous solution. 
     
     
       13. The catalyst of  claim 12 , wherein the temperature of the aqueous solution is maintained at room temperature. 
     
     
       14. The catalyst of  claim 1 , wherein the non-evaporative separation technique comprises decanting. 
     
     
       15. A method of forming a hydrogenating-metal-containing zeolite catalyst for use in aromatic alkylation, the method comprising:
 treating a ZSM-5 zeolite with a phosphorus-containing compound to form a phosphorus-treated zeolite; 
 combining the phosphorus-treated zeolite with a binder material to form a bound phosphorus-treated zeolite; 
 treating the bound phosphorus-treated zeolite with an aqueous solution of a hydrogenating metal compound by contacting the bound phosphorus-treated zeolite with the aqueous solution to form a hydrogenating-metal-containing zeolite in an aqueous medium, wherein the hydrogenating metal is Group VIII transition metal; 
 separating the aqueous medium from the bound phosphorus-treated zeolite using a non-evaporative separation technique; and 
 calcining to form the hydrogenating-metal-containing zeolite catalyst. 
 
     
     
       16. The method of  claim 15 , wherein the temperature of the aqueous solution is maintained at a temperature below the boiling point of the aqueous solution. 
     
     
       17. The method of  claim 16 , wherein the temperature of the aqueous solution is maintained at room temperature. 
     
     
       18. The method of  claim 15 , wherein the non-evaporative separation technique comprises decanting. 
     
     
       19. The method of  claim 15 , wherein the hydrogenating metal is selected from at least one of nickel, palladium, and platinum. 
     
     
       20. The method of  claim 19 , wherein the hydrogenating metal comprises nickel. 
     
     
       21. The method of  claim 20 , wherein the nickel is present in the catalyst in an amount of about 0.03% to about 2% by total weight of catalyst. 
     
     
       22. The method of  claim 15 , wherein the catalyst contains about 0.01% to about 15% phosphorus by total weight of catalyst.